Nozzle brush arrangements for vacuum cleaner assemblies

ABSTRACT

A vacuum cleaner assembly is disclosed. The vacuum cleaner assembly comprises at least one brushroll and at least one nozzle brush. The brushroll is rotatably supported about a first axis within the vacuum cleaner and is operatively connected to a motor. The nozzle brush is operatively connected to the brushroll and configured to rotate about a second axis. When the brushroll is rotated about the first axis, the nozzle brush is actuated to rotate about the second axis.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 61/110,797 filed Nov. 3, 2008 which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

This disclosure is generally related to vacuum cleaners and, more particularly to vacuum cleaner bases with rotating brush arrangements.

BACKGROUND

Vacuum cleaners are used to pick up dirt and debris that has become deposited or embedded into various floor types. To improve performance of vacuum cleaners, some vacuum cleaners employ a revolving brushroll to loosen up dirt and debris, so an air flow created by the vacuum cleaner may entrain such dirt and debris. Additionally, brushrolls have generally been configured to rotate in a manner to push the dirt and debris toward an opening to a vacuum chamber, in the pathway of the air flow, such that the dirt and debris get picked up and deposited into canister for disposal.

Brushrolls are generally contained in housings that prevent the brushroll from extending all the way to the edge or through the edge of the housing so as prevent the rotating brushroll from projecting dirt and debris up into the air rather than into the opening of a vacuum chamber. As a result, brushrolls are generally contained within a housing which, in turn, creates a gap between the outer edge of the housing and the brushroll. When vacuuming up against a wall in a room this gap prevents the brushroll from being able to loosen dirt and debris on the edge of the floor abutting the wall. While one solution to cleaning this edge of the floor abutting the wall is to use an attachment wand and nozzles that are connect to the vacuum chamber, such an arrangement requires reconfiguring the setup of a vacuum cleaner, increasing cleaning time.

Therefore, what is needed is a vacuum cleaner design that can effectively loosen dirt and debris, like the rotating brushroll, but also provide such action to the edge of a vacuum cleaner housing without requiring additional reconfiguration of the vacuum cleaner through the use of external attachment accessories.

SUMMARY

A vacuum cleaner assembly is disclosed. The vacuum cleaner assembly comprises at least one brushroll and at least one nozzle brush. The brushroll is rotatably supported about a first axis within the vacuum cleaner and is operatively connected to a motor. The nozzle brush is operatively connected to the brushroll and configured to rotate about a second axis. When the brushroll is rotated about the first axis, the nozzle brush is actuated to rotate about the second axis.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial perspective view of a vacuum cleaner base.

FIG. 2 is a partial plan view of a first nozzle brush arrangement.

FIG. 3 is a perspective view of a vacuum cleaner base.

FIG. 4 a plan view of an underside of the vacuum cleaner base of FIG. 3, illustrating a second nozzle brush configuration.

FIG. 5 a plan view of the underside of the vacuum cleaner base of FIG. 4, with a cover panel removed.

FIG. 6 is a partial perspective view of a gear housing used with a brushroll and nozzle brush arrangement.

FIG. 7 is a cross-sectional view of a forward portion of a vacuum cleaner base.

FIG. 8 is an exploded view of a casing that mounts a brushroll and nozzle brush arrangement.

FIG. 9 is a partial cross-sectional view of a vacuum cleaner base having a nozzle brush therein, wherein the vacuum cleaner is engaged against a wall.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, illustrative and exemplary embodiments of the present disclosure are shown in detail. Although the drawings represent some embodiments of the present disclosure, the drawings are not necessarily to scale and certain characteristics may be exaggerated to better illustrate and explain the present disclosure. Further, the embodiments set forth herein are not intended to be exhaustive or otherwise limit or restrict the disclosure to the precise forms and configurations disclosed in the following detailed description.

FIGS. 1-8 provide alternative arrangements of a brushrolls and nozzle brushes used in vacuum cleaners. While shown positioned in a vacuum cleaner base, such as vacuum cleaner bases 10 and 100, respectively, it is understood that the brushroll and nozzle brush arrangements may be used in other types of vacuum cleaner configurations. The vacuum cleaner assemblies employing the brushrolls and nozzle brushes arrangements may be used on a variety of surfaces such as generally planar flooring, including tiles, cement, wood, paneling; as well as on carpeting or other textured surfaces.

Referring now to FIG. 1, a perspective view of an exemplary embodiment of vacuum cleaner base 10 is shown. Vacuum cleaner base 10 includes an outer portion 12, a panel cover 14, one or more wheels 16, a projection portion 18, and a nozzle brush 20. A light (not shown), may also be attached to outer portion 12. Outer portion 12 may be made of a unitary piece of durable material, such as plastic, or a blend of synthetic materials that are durable and sturdy. In one exemplary embodiment, outer portion 12 is injection molded for ease of manufacturer. It is contemplated that outer portion 12 may be made of more than one piece of durable sturdy material, held together with suitable fasteners of various types. The shape of outer portion 12 may be designed and manufactured to fit the contents and structures contained within vacuum cleaner base 10. Thus, it is contemplated that the shape of outer portion 12 may vary greatly between embodiments.

Wheels 16 are depicted in FIG. 1 as being positioned adjacent a rear end 17 of vacuum cleaner base 10, also adjacent projection portion 18 of the vacuum cleaner base 10. However, it is contemplated that there may be more than one wheels 16 and that any of wheels 16 may be rearranged to different positions within vacuum cleaner base 10, depending on the desired design of the vacuum cleaner base 10. Wheels 16 help facilitate the movement of vacuum cleaner base 10 when attached to a vacuum cleaner body (not shown). Wheels 16 may vary in size, type (such as swivel, mechanized, spherical, etc.), and the types of materials used to make wheels 16 may range from a variety of durable materials including plastics, rubber or a blend of thereof.

In one exemplary embodiment, projection portion 18 may be pivotally attached to the body of the vacuum cleaner (not shown). Projection portion 18 serves as a conduit to deliver debris to a vacuum receptacle of the vacuum cleaner body (not shown). As shown, projection portion 18 may be configured to extend outwardly from the vacuum cleaner base 10. Further, projection portion 18 may serve to provide stability and support between vacuum cleaner base 10 and the vacuum cleaner body (not shown). For example, projection portion 10 may support an attached vacuum canister, vacuum motor and a handle in an upright vacuum cleaner arrangement. In yet another exemplary arrangement, projection portion 10 may support a handle and a hose leading to the vacuum cleaner body.

Further, projection portion 18 may be configured to facilitate a pivoting motion of the vacuum body with respect to vacuum cleaner base 10 during operation. Projection portion 18, together with wheels 16, facilitates the ease of moving vacuum cleaner base 10 over and across a targeted surface. Projection portion 18 may be made of the same material as outer portion 12. Projection portion 18 may also be made out of the same piece as outer portion 12 or may be made from a separate piece and then attached to vacuum cleaner base 10 using a variety of suitable fasteners. It is contemplated that other materials, such as those materials suitable for outer portion 12, may also be used to make projection portion 18.

FIG. 2 depicts the underside of the vacuum cleaner base 10. As shown, in addition to nozzle brush 20, positioned within vacuum cleaner base 10 is also at least one brushroll 26. Brushroll 26 is generally configured as an elongated member and has a plurality of bristles 27 extending from an external surface 29 thereof. While shown as being arranged in a spiral pattern, it is understood that bristles 27 may be arranged in a variety of patterns. Brushroll 26 is mounted within a cavity 28 such that at least bristles 27 extend through an opening 30 formed in panel cover 14 and positioned adjacent a forward edge 31 of vacuum cleaner base 10. Bristles 27 may be directly attached to external surface 29 of brushroll 26. Cavity 28 is in fluid communication with an air flow channel (not shown).

In an alternative arrangement, bristles 27 may be mounted on a substrate. In such an arrangement, brushroll 26 includes a slot that is configured to receive bristles 27 such that bristles 27 extend outward from the slot (as explained below in connection with FIG. 8 in greater detail).

In one exemplary embodiment, brushroll 26 is configured to be predominantly cylindrical in shape, but may include various grooves or channels formed in external surface 29 of brushroll 26 to facilitate mechanical communication with other structures within vacuum cleaner base 10. For example, a center portion 32 of the elongate brushroll 26 may be configured with a groove 34 to which a drive belt (not shown) is mounted to facilitate mechanical communication between a motor (not shown) and brushroll 26. In one particular arrangement, disposed on either side of groove 34 is a retaining flange 34 that assists with retaining the drive belt on brushroll 26. In another embodiment, a pair of brushrolls 26 are used, the brushrolls 26 being connected together with a mounting portion that receives the drive belt.

The brushroll 26 may be constructed from wood, or any other durable and sturdy material, as described above. It is also contemplated that brushroll 26 may vary in thickness throughout the span of brushroll 26. It may be tapered at certain portions or it may have a uniform thickness throughout.

In the embodiment shown in FIG. 2, attached to distal ends 36 of brushroll 26 are spindles 42. Spindles 42 receive rotary belts 44 that also attach to nozzle brushes 20 to promote rotation of nozzle brush 20 when brushroll 26 rotates. More specifically, spindles 42 support and stabilize rotary belt 44. Each rotary belt 44 wraps around a base of a nozzle brush 20, which may also be configured with a mounting groove (not shown) formed thereon to secure rotary belt 44 during rotation about a vertical axis. As depicted in one exemplary embodiment, nozzle brushes 20 are positioned rearward of the brushroll 26. However, it is understood that nozzle brush 20 may also be positioned forward of brushroll 26.

In one exemplary embodiment, vacuum cleaner base 10 may be configured with an air flow groove 53 (shown in phantom in FIG. 1). Air flow groove 53 may be formed through a portion of a vacuum cleaner and leads into cavity 28 so as to be in fluid communication with a recess formed in vacuum cleaner base 10, adjacent brushroll 26 and the air channel formed therein. Generally, air flow groove 53 is positioned adjacent to nozzle brush 20 and particularly close to a pathway where nozzle brush 20 may direct dirt and debris to.

Air flow groove 53 is configured to have a predetermined size to create a low pressure area inside vacuum base 10. Such a low pressure area assists in creating a relatively high air flow rate through cavity 28, the recess and aperture formed within vacuum cleaner base 10 (described in further detail in connection with the embodiment shown in FIGS. 3-5), and into the air channel. The high air flow forces dirt and debris (including hard objects) that may be continuously rotating about brushroll 26 due to centripetal forces generated thereby, to be directed into the air channel 32. Thus, the relatively high air flow allows a vacuum cleaner effectively direct dirt and debris loosened up or pushed into the air channel of the vacuum system by brushroll 126 and nozzle brush 120.

FIG. 3 illustrates a perspective view of an alternative embodiment of a vacuum cleaner base 100 and FIG. 4 illustrates the underside thereof. Vacuum cleaner base 100 includes an outer portion 112, a panel cover 114, one or more wheels 116, a projection portion 118, and at least one nozzle brush 120. A light 158 may also be attached to outer portion 112. As may be seen, in this embodiment, nozzle brushes 120 are positioned adjacent a forward edge 121 of vacuum cleaner base 100.

Referring to FIG. 4, it can be seen that panel cover 114 substantially covers and at least partially seals off the structures within and contents of vacuum base 100. Panel cover 114 is depicted in FIG. 4 as one continuous piece but it is contemplated that panel cover 114 may be made up of more than one piece. Panel cover 114 is relatively flat as it engages with a targeted surface. However, panel cover 114 may include varying shaped depressions and extrusions depending on what structure it is covering. Panel cover 114 may be held in position by any number of fasteners suitable to secure panel cover 114 in position during use and at rest. It is contemplated that panel cover 114 will vary in shape and design depending on the shape and design of the corresponding base. Panel cover 114 may be made from the same or similar materials as the outer portion.

A substantial portion of a cavity 128 is exposed through an opening 130 formed in the panel cover 114. A rotating brushroll 126 is positioned within cavity 128. Brushroll 126 is configured to carry bristles 127. Bristles 127 may be attached directly to an outer surface 129 of brushroll 126, or, alternatively, indirectly to brushroll 126. More specifically, bristles 127 may be mounted to a substrate that is removably received within brushroll such that bristle 127 may extend outwardly from a channel formed through outer surface 129 of brushroll.

Cavity 128 may be formed in part by a casing 152 as depicted in FIG. 7 or upper casing 152a and lower casing 152b as depicted in FIG. 8. Casing 152 may be made of one piece or multiple pieces and out of a variety of materials including metals and plastics. Casing 152 may also be formed out of a portion of outer portion 12 or may be independently attached to vacuum base 100.

Turning now to FIG. 5, the underside of vacuum cleaner base 100 with panel cover 114 removed is shown. An air channel 132 is positioned within vacuum cleaner base 100. Air channel 132 is fluidly connected with an opening of a vacuum chamber (not shown) that is generally located in the body of the vacuum cleaner (not shown). The opening of the vacuum chamber may be partially formed from projection portion 118 of vacuum cleaner base 100, although it may alternatively be formed separately from the projection portion 118. Air channel 132 may also be formed partially from projection portion 118.

Also contained within vacuum cleaner base 100 is a motor 140. In one exemplary arrangement, motor 140 is at least partially covered by both outer portion 112 and panel cover 114 (removed). Motor 140 is connected to a motor arm 136. In one exemplary arrangement, motor arm 136 extends axially into air channel 132. Many variations of motors are suitable for use in the vacuum cleaner; especially those used and sold by Rexair, Inc., the assignee of the present disclosure. Two examples of suitable motors are described in the U.S. Pat. Nos. 5,949,175 and 6,777,844, each incorporated herein by reference in their entirety.

Brushroll 126 is generally cylindrically-shaped but may include various grooves or channels formed in external surface 129 to facilitate mechanical communication with other structures within vacuum cleaner base 100. For example, a center portion 133 of brushroll 126 may be configured with a groove 134 to which a drive belt 138 is mounted to facilitate mechanical communication between motor 140 and brushroll 126. In one particular arrangement, disposed on either side of groove 134 is a retaining flange 135 that assists with retaining drive belt 138 on brushroll 126. In another embodiment, a pair of brushrolls 126 are used, the brushrolls 126 being connected together with a mounting portion that receives drive belt 138.

In one embodiment, brushroll 126 may be constructed from wood. However, it is also contemplated that brushroll 126 may be made from any number of durable and sturdy materials previously described above. It is also contemplated that brushroll 126 may vary in thickness throughout the span of brushroll 126. It may be tapered at certain portions or it can have a uniform thickness throughout.

In one embodiment, bristles 127 attached to brushroll 126 are arranged in a spiral pattern. More specifically, bristles 127 on brushroll 126 are depicted in FIG. 5 as two spiral-patterned rows integrated into brushroll 126. However, it is contemplated that more bristle rows may be present on brushroll 126 and that the pattern with which the rows are arranged may vary from the depicted spiral design to a chevron design or other arrangements.

As discussed above, in some embodiments the bristles 127 are removably attached or replaceable as illustrated in FIG. 8. It is desirable to have bristles 127 that are sturdy enough to loosen debris and dirt from the targeted surface without causing damage to the surface such as unnecessary scratching, scuffing or snagging of the surface. Any number of suitable materials that are well known in the art can be used for this purpose.

In addition, bristles 170 on nozzle brush 120 may be removably attached or replaceable. Bristles 170 of both nozzle brush 120 and the elongate brushroll 126 may be made of various materials exhibiting a variety of properties, wherein some are thicker, coarser, and stiffer in nature while others are finer, softer, and less stiff. A variety of types and materials the bristles are made of such as plastics, acrylics, resins, goat hair and so forth, that exist are known in the art and made to be adaptable to a particular surface that is to be cleaned. Bristles 170 of the nozzle brush 120 shown in FIG. 7 ideally exhibit the same sturdy qualities as those bristles 127 on brushroll 126. Bristles 170 may be arranged in rows, bunches, partially or completely covering the outermost surface of the power nozzle brush 120. A bristle-less brushroll or nozzle brush is also conceivable wherein the material used is designed to facilitate the uptake of dirt and debris.

A recess 154 may be formed in vacuum cleaner base 100, as shown in FIG. 7. Recess 154 aides in facilitating uptake of debris that contains small hard objects that would otherwise spit back out. Recess 154, as shown, has an angled surface 155. Angled surface 155 is oriented so as to have a first end 157 that is positioned axially lower than a second end 159. With this configuration dirt and debris is directed upwardly in recess 154 from brushroll 120, along angled surface 155 to cause such dirt and debris to move towards an aperture 156 that opens into air channel 132, shown in FIG. 5. Hard objects are either directed into air channel 132 or contained in recess 154 until they are drawn into air channel 132. In one embodiment recess 154 is configured to create a vortex-like tunnel that pulls dirt and debris caught in the recess 154 from outer edges of casing 152 into a center portion where aperture 156 fluidly communicates with air channel 132. Recess 154 may span the length of the casing 152, enclosing brushroll 126 or may vary in length. In some arrangements, recess 154 may even be comprised of sections.

In some arrangements, as best seen in FIGS. 6-7, an air flow groove 153 is formed through a portion of a vacuum cleaner into cavity 128. More specifically, in one particular arrangement, air flow groove 153 is formed through an outer portion of gear housing 150 or vacuum base 100 and extends into cavity 128. Thus, air flow groove 153 is in fluid communication with recess 154, aperture 156 and air channel 132. Generally, air flow groove 153 is positioned adjacent to nozzle brush 120 and particularly close to the path that nozzle brush 120 may direct dirt and debris to. In one exemplary arrangement, air flow groove 153 is arranged so as to be adjacent to a dust pan region 161. Dust pan region 161 cooperates with air flow groove 153 to retain dirt and debris within recess 154 until such dirt and debris may be drawn through aperture 156 of air channel 132.

Air flow groove 153 is configured to have a predetermined size to create a low pressure area inside vacuum base 100. In one exemplary arrangement, air flow groove 153 is approximately ¼ inches wide and ⅛ inches in height. Such a low pressure area assists in creating a relatively high air flow rate through cavity 128, recess 154 and aperture 156, into air channel 132. The high air flow forces dirt and debris (including hard objects) that may be continuously rotating about brushroll 126, due to centripetal forces, to be directed into air channel 132. Thus, the relatively high air flow allows a vacuum cleaner to effectively direct dirt and debris loosened up or pushed into the air channel 132 of the vacuum system by brushroll 126 and nozzle brush 120.

In one arrangement, positioned at each end of brushroll 126 are worm gears 124, seen best in FIG. 6. In an alternative embodiment, a bearing housing 130 is positioned adjacent to each worm gear 124, between the end of brushroll 126 and worm gears 124, best seen in FIG. 5. In both of these embodiments, worm gears 124 and the bearing housings 130 rotate in sync with brushroll 126, about a first axis. Specifically, motor 140 positioned within vacuum base 100 rotates motor arm 136. Drive belt 138 is positioned such that it is wrapped around both motor arm 136 and a portion of brushroll 126. As motor 140 axially rotates motor arm 136 about an axis, drive belt 138 rotates around both motor arm 136 and brushroll 126, facilitating continuous revolutions about a first axis. Worm gears 124, and if applicable, adjacent bearing housings 130, also rotate about the first axis, in sync with elongate brushroll 126.

In another embodiment (not shown), a motor 140 operatively communicates with brushroll 126 and may be attached to a drive shaft (not shown) that causes brushroll 126 to rotate about the first axis, which may be oriented to be generally horizontal with respect to an engaged surface or ground. Additionally, in one embodiment, (not shown) a motor may be positioned externally of vacuum base 100 and in operative communication with brushroll 127 through a turbine system. The motor draws in air which in turn causes rotational movement of brushroll 127 through a turbine driven system. This particular embodiment may be incorporated into a handheld version of a vacuum base wherein at least one nozzle brush is rotated through brushroll 127 driven by a turbine motor system.

Referring specifically to the arrangements depicted in FIGS. 3-6 and 8, rotatable nozzle brush 120 is depicted as positioned on a forward outer edge 141 of vacuum base 100 so as to extend outwardly from the vacuum base 100. In an exemplary embodiment, a pair of rotatable nozzle brushes 120 are partially situated in gear housings 150 (best seen in FIG. 6) adjacent each end of the elongate brushroll 126. Each gear housing 150 contains a worm gear 124 and spur gear 148 as shown in FIG. 6. The outer circumference of nozzle brush 120 may carry a gear having a plurality of gripping teeth protruding radially outwardly there from such as those adapted for various types of gears including spur, worm, hypoid, bevel and any type of system having a driving portion attached to brushroll 126 and a driven portion attached to nozzle brush 120. For instance in FIG. 6, a worm gear 124 mechanically engages the plurality of gripping teeth of spur gear 148 on the corresponding nozzle brush 120, as shown. As worm gear 124 rotates about its axis, spur gear 148 causes nozzle brush 120 to rotate about a second axis with each revolution of worm gear 124. The driving portion of gear 124 is contemplated to be made of a metallic material such as stainless steel, a plastic or polymer based material including, but not limited to, Entech nylon66 and Ashland Zytel WRF 500, or other suitable resin material. Likewise, the driven portion may also be made of similar materials as to that of the driving portion. Any combination of the materials mentioned above or those having similar characteristics as recognized by those skilled in the art are conceivable.

One particular embodiment using a gear system to mechanically rotate a nozzle brush 120 through a brushroll 126 comprises using a bath of grease such as Molbilux EP 023 to ensure adequate lubrication and prevent wearing. However, in one particular embodiment a gear system devoid of any grease is possible. More specifically, where the driving portion is made of a stainless steel while the driven portion is made of plastic material. Such an arrangement of a greaseless or tubeless system is advantageous when cleaning floors as such lubricants may soil the engaged surface if they were to leak out of the system.

One particular advantage of a gear system driving nozzle brushes 120 through brushroll 126 is the ability to adjust the torque and speed relationships between brushroll 126 and the power nozzle brush 120. It has been found that rotating brushroll 126 at higher speeds tend to loosen dirt and debris caused by the rotating beating action of bristles 127. However, rotating nozzle brush 120 at a lower rotational speed than brushroll 126 has been found to be more effective than rotating nozzle brush 120 at a high rotational speed as too high of a speed tends to project dirt and debris beyond the intended intake of vacuum base 100. The ratio of the speeds of nozzle brush 120 to brushroll 126 may be of the range 1:1. 1:5, 1:10 and 1:20 wherein brushroll 126 rotates 20 times faster than nozzle brush 120. Other non-gear systems are also conceived to adjust the ratio of speed as discussed below.

Nozzle brush 120 may be secured to vacuum base 100 or gear housing 150 within vacuum base by a suitable fastener 122 such as a stud, pin or a screw, traversing the center of nozzle brush 120, so as not to hinder rotation about the second axis. Plain or ball bearings (not shown) may be press fit onto or otherwise attached to 122 facilitating rotational movement. A gear such as spur gear 148 may be press fit, pinned or molded onto fastener 122. Other fastening means may be contemplated as alternatives for attaching nozzle brush 120 to vacuum base 100 as well. More particularly, those that may be easily removed and allow nozzle brush 120 to be selectively detached. Nozzle brush 120 is generally circular in shape with bristles 170 protruding from the outermost surface of nozzle brush 120; specifically, they protrude from the surface that engages the targeted surface.

It is further contemplated that additional nozzle brushes 120 may be added to vacuum cleaner base 100 in alternate embodiments. It is also contemplated that nozzle brush 120 may be positioned on the outer edges of vacuum cleaner base 100 or positioned more internally, for example, near the air channel 132 of the base 100. FIGS. 1-2 show embodiments where nozzle brush 20 is placed on an outer edge of vacuum cleaner base 10 behind brushroll 26. FIGS. 3-5 illustrate embodiments where nozzle brush 120 is placed on a forward corner of vacuum cleaner base 100, adjacent brushroll 126. FIG. 9 illustrates a specific operation of the embodiments shown in FIGS. 3-5. More specifically, as nozzle brush 120 engages a target surface 200 to be cleaned, nozzle brush 120 is able to reach debris 204 deposited adjacent a wall 202.

As previously stated, it is contemplated that the number and position of nozzle brushes 20, 120 may vary between embodiments. It is contemplated that some nozzle brushes 20, 120 are powered by alternative means, other than through the operation of brushroll 26, 126. For instance, nozzle brushes 20, 120 may be directly powered by motor 140. It is also contemplated that nozzle brushes 20, 120 may be used to drive brushroll 26, 126. Other power mechanisms operatively communicating between brushroll 26, 126 and nozzle brush 20, 120 using a flex shaft, and magnetic clutches.

In all of the described embodiments, as vacuum cleaner base 10, 100 engages a targeted surface, the combination of rotation of brushroll 26, 126, and nozzle brush 20, 120, create a powerful source of agitation that promotes and enhances the loosening, collection and uptake of dirt and debris from the surface. Nozzle brush 20, 120 increases the area of the targeted surface that can be reached and cleared of dirt and debris by adding a substantial amount of spinning power that can grab more dirt and debris as compared to a vacuum cleaner without a nozzle brush 20, 120 configuration.

Rotation and beating of bristles 27, 127 of brushroll 26, 126 onto an engaged surface, mixed with the rotation and vibrations of the spinning bristles 170 on nozzle brush 20, 120, facilitate the uptake of dirt and debris particles as they are drawn into cavity 28, 128. The dirt and debris then pass through an opening or aperture 156 as shown in FIG. 7. Bristles 27, 127 of brushroll 26, 126 may be configured to direct dirt and debris toward the center of brushroll 26, 126 where they are then pushed or drawn through aperture 156 into air channel 132 that may be formed, in part, by projection portion 18, 118 of vacuum cleaner base 10, 100 and continuously drawn through the opening of the vacuum chamber (not shown). From there it passes to the body of the vacuum cleaner (not shown) where the dirt and debris may run through a filtering process and eventually end up in a receptacle (not shown) where it is stored until it is discarded. It is contemplated that these events can occur within many types of vacuums including a standard upright vacuum.

In one exemplary embodiment, the height and position of vacuum cleaner base 10, 100 in relation to the surface to be cleaned may be selectively adjustable, such as raised away from the surface, to allow for thicker surfaces such as carpeting, or lowered to be closer to more planar-like surfaces such as wood floors. Additionally, it is contemplated the height of brushroll 26, 126 and nozzle brush 20, 120 may also be selectively adjusted with respect to the engaged surface. It is also contemplated that the angle of the second axis about which nozzle brush 20, 120 rotates may be selectively adjusted with respect to the engaged surface.

The appended claims have been particularly shown and described with reference to the foregoing embodiments, which are merely illustrative of the best modes for carrying out the invention defined by the appended claims. It should be understood by those skilled in the art that various alternatives to the embodiments described herein may be employed in practicing the invention defined by the appended claims without departing from the spirit and scope of the invention as defined in claims. The embodiments should be understood to include all novel and non-obvious combinations of elements described herein, and claims may be presented in this or a later application to any novel and non-obvious combination of these elements. Moreover, the foregoing embodiments are illustrative, and no single feature or element is essential to all possible combinations that may be claimed in this or a later application.

With regard to the processes, methods, heuristics, etc. described herein, it should be understood that although the steps of such processes, etc. have been described as occurring according to a certain ordered sequence, such processes could be practiced with the described steps performed in an order other than the order described herein. It further should be understood that certain steps could be performed simultaneously, that other steps could be added, or that certain steps described herein could be omitted. In other words, the descriptions of processes described herein are provided for illustrating certain embodiments and should in no way be construed to limit the appended claims.

Accordingly, it is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments and applications other than the examples provided would be apparent to those of skill in the art upon reading the above description. The scope of the invention should be determined, not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. It is anticipated and intended that future developments will occur in the arts discussed herein, and that the disclosed systems and methods will be incorporated into such future embodiments. In sum, it should be understood that the invention is capable of modification and variation and is limited only by the following claims.

All terms used in the claims are intended to be given their broadest reasonable constructions and their ordinary meanings as understood by those skilled in the art unless an explicit indication to the contrary is made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary. 

1. A vacuum cleaner, comprising: at least one brushroll rotatably supported about a first axis housed within the vacuum cleaner, wherein the brushroll is operatively connected to a motor; at least one nozzle brush operatively connected to the brushroll and configured to rotate about a second axis such that when the brushroll is rotated about the first axis, the nozzle brush rotates about the second axis; an air channel positioned within the vacuum cleaner; and an air flow groove formed through a portion of the vacuum cleaner such that the air flow groove communicates with an exterior of the vacuum cleaner and the air channel formed in the vacuum cleaner.
 2. The vacuum cleaner of claim 1, further comprising a first gear fixedly secured to one end of the brushroll, wherein the gear is rotatably driven by the brushroll and is operatively connected to the nozzle brush.
 3. The vacuum cleaner of claim 2, wherein the first gear is comprised of at least a driving portion and a driven portion.
 4. The vacuum cleaner of claim 3, wherein the driving portion is comprised of a metallic material.
 5. The vacuum cleaner of claim 3, wherein the driven portion is comprised of a plastic material.
 6. The vacuum cleaner of claim 2, wherein the first gear may be one of a spur, worm, hypoid, or bevel gear.
 7. The vacuum cleaner of claim 1, wherein the nozzle brush includes a base portion having a groove formed thereon.
 8. The vacuum cleaner of claim 7, further including at least one spindle fixedly secured to one end of the brushroll, wherein the spindle is rotatably driven by the brushroll and is operatively connected to the nozzle brush.
 9. The vacuum cleaner of claim 8, further comprising a rotary belt engaged with the spindle and the groove formed in the nozzle brush.
 10. The vacuum cleaner of claim 1, wherein the first axis about which the brushroll rotates is positioned so as to be substantially horizontal with respect to an engaged surface and wherein the second axis about which the nozzle brush rotates is substantially vertical with respect to the engaged surface.
 11. The vacuum cleaner of claim 1, wherein a distance between the brushroll and a surface to be engaged by the brushroll is selectively adjustable.
 12. The vacuum cleaner of claim 1, wherein a distance between the nozzle brush and a surface to be engaged by the nozzle brush is selectively adjustable.
 13. The vacuum cleaner of claim 1, wherein the nozzle brush further comprises removably attached bristles.
 14. The vacuum cleaner of claim 1, wherein the brushroll further comprises removably attached bristles.
 15. The vacuum cleaner of claim 1, further comprising a casing that houses the brushroll within the vacuum cleaner, wherein the casing further comprises an angled recess configured to facilitate the uptake of debris.
 16. The vacuum cleaner of claim 15, wherein one edge of the recess is positioned to direct debris into an aperture formed in a housing of the vacuum cleaner, wherein the aperture is in fluid communication with an air channel formed in the housing that fluidly communicates with an opening of the vacuum chamber.
 17. The vacuum cleaner of claim 1, further including a motor shaft mechanically communicating with the motor, wherein the motor arm engages a drive belt that is operatively connected to the brushroll.
 18. The vacuum cleaner of claim 1, further including a drive shaft connected with the motor, wherein the drive shaft is operatively connected to the brushroll to rotate the brushroll.
 19. The vacuum cleaner claim 1, wherein the nozzle brush rotates in sync with the brushroll.
 20. The vacuum cleaner of claim 1, wherein the brushroll operates at a first predetermined rotational speed and the nozzle brush operates at a second predetermined rotational speed.
 21. The vacuum cleaner of claim 20, wherein the ratio of the first and second predetermined rotational speeds ranges from 1:1 to 1:20.
 22. The vacuum cleaner of claim 1, further comprising a recess formed adjacent the brushroll, wherein the recess comprises an angled surface configured to direct debris toward an aperture of the air channel and away from the brushroll.
 23. A vacuum cleaner assembly, comprising: a base having an outer portion, a panel cover, and one or more wheels; a motor positioned within a housing, the housing having an aperture that is in communication with an air channel that fluidly communicates with an opening of a vacuum chamber within a body of the vacuum cleaner assembly; a motor shaft connected to the motor and engaged with a drive belt, wherein the drive belt is operatively connected to a brushroll positioned in the base; a worm gear is attached to each end of the brushroll, such that rotation of the brushroll also rotates each worm gear in sync with the brushroll; a nozzle brush in operative engagement with each worm gear, wherein rotation of the brushroll rotates the nozzle brush to facilitate loosening and uptake of debris on a surface engaged by the vacuum cleaner assembly; and a recess formed adjacent the brushroll, wherein the recess comprises an angled surface configured to direct debris toward the aperture and away from the brushroll.
 24. A vacuum cleaner assembly, comprising: a base having an outer portion, a panel cover, and one or more wheels; a motor positioned within a housing that is seated within the base, the housing having an aperture in communication with an air channel that fluidly communicates with an opening of a vacuum chamber within a body of the vacuum cleaner assembly; a motor shaft connected to the motor and engaged with a drive belt, wherein the drive belt is operatively connected to a brushroll positioned in the base; wherein the brushroll further includes at least one spindle positioned at an end thereof; at least one nozzle brush positioned within the base; a rotary belt wrapped around the spindle and a portion of the nozzle brush, wherein the nozzle brush rotates in response to the rotation of the brushroll to facilitate loosening and uptake of debris on a surface engaged by the vacuum cleaner assembly. 